Mosaic Manufacturing Launches Orion, an Automated 3D Printing Platform for Custom Orthotics

A Purpose-Built System for Orthotics

Mosaic Manufacturing has entered the orthotics market with Orion, a new automated 3D printing platform designed from the ground up for custom foot orthotics production. The system was developed after extensive conversations with clinicians and manufacturers who were struggling to transition to digital production methods.

Orion uses a belt-based 3D printing architecture combined with automated queue management, allowing the printer to continuously produce orthotics overnight and on weekends without constant human supervision. The system supports both soft and rigid patient-specific orthotics using Mosaic's proprietary materials.

Reducing Cost and Complexity

According to Mosaic CEO Mitch Debora, the fragmented tools on the market made digital orthotics production painful to implement. The Orion addresses this by offering an end-to-end, validated solution that clinics and labs can deploy confidently.

The company says the platform can produce up to 300 pairs of orthotics per month, with material costs as low as $6 per pair. The system also reduces material waste and eliminates most of the hand-finishing work that traditional methods require.

Open Architecture Workflow

The full Mosaic Stryde Software Suite manages the workflow from digital scanning through design and production management. Facilities that already have a digital pipeline can connect Orion to compatible CAD/CAM setups instead.

The launch represents a practical step toward making digital orthotics production accessible to smaller clinics and labs that previously lacked the budget or staffing to invest in industrial AM systems.